Coolant circulation system for electrical discharge machining apparatus



June 25, 1968 k, s, WEBB 3,390,241

COOLANT CIRCULATION SYSTEM FOR ELECTRICAL DISCHARGE MACHINING APPARATUS Original Filed Feb. 24, 1961 3 Sheets-Sheet 1 /J1 /J0 4 F 74 /J4 GTEQ- g? E j w --//Z,'E Z -Z V 7 7 2 2 /jfl 1 i 44 j; jg INVENTOR. s W I I I 2702;; s. 4&2.

' BY ///7;//// j -1 a 9 June 25, 19.68 R. s, W 3,390,247

COOLANT CIRCULATION SYSTEM FOR ELECTRICAL DISCHARGE MACHINING APPARATUS Original Filed Feb. 24. 1961 3 Sheets-Sheet 2 //4 A j W W //a E I I v A I 1 E i: 2 F0207; 33E 2 BY a 9 June 25, 1968 R. s. WEBB 3,390,247

' COOLANT CIRCULATION SYSTEM FOR ELECTRICAL DISCHARGE MACHINING APPARATUS Original Filed Feb. 24, 1961 5 Sheets-Sheet 5 W a w 2 1 A 5 z i f INVENTOR.

United States Patent 3,390,247 COOLANT CIRCULATION SYSTEM FOR ELEC- TRICAL DISCHARGE MACHINING APPARATUS Robert S. Webb, Bloomfield Hills, Mich., assiguor, by

mesne assignments, to Elox Inc., Troy, Mich, a corporation of Delaware Continuation-impart of application Ser. No. 469,578, July 6, 1965, which is a continuation of abandoned application Ser. No. 91,457, Feb. 24, 1961. This application June 27, 1966, Ser. No. 560,670

4 Claims. (Cl. 219-69) ABSTRACT OF THE DISCLOSURE An EDM dielectric-liquid circulation system incl-uding an electrode having protuberant and reentrant face areas and circulation passages extending through the electrode and opening medially of said face areas. Positive or negative pressure may be applied to the liquid to cause it to flow out of or into either passage at the EDM gap, to cool, deionize and flush the gap.

This application is a continuation-in-part of my 00- pending application Ser. No. 469,578, filed July 6, 1965, entitled Electrical Machining Apparatus, which application is a continuation of my application 'Ser. No. 91,457, filed Feb. 24, 1961, now abandoned.

Electrical discharge machining, commonly referred to in the art as EDM or spark machining, is a type of electrical machining carried on by passing a series of relatively low voltage, high current, high frequency, localized discharge-s across a gap between an electrode and a conductive workpiece in the presence of a dielectric fluid.

In electrical discharge machining, the conductive electrode is maintained in proximate position with the workpiece by an automatic servo feed and is advanced toward or into the workpiece as stock is removed therefrom. A fluid coolant is circulated or flushed through the working gap, usually furnished under pressure by a pump and circulated through a pattern of holes in the electrode. This coolant is by definition a dielectric and is nearly always a liquid, such as kerosene or transformer oil.

An example of an electrical discharge power circuit for providing rectangular machining pulses to the gap of a polarity to render the electrode positive and the workpiece negative is shown in my Letters Patent No. 3,158,- 728, issued Nov. 24, 1964. An example of an automatic servo feed control to maintain optimum machining gap spacing is shown in my Patent No. 2,962,630, issued Nov. 29, 1960. That patent shows the control circuitry and means for operating the hydraulic servo system shown in part in FIGS. 1 and 2 of the attached drawings.

In electrical discharge machining, I have found that a problem exists in the normal liquid circulating system. The liquid when compressed by the circulating pump tends to decompose and form gas or tends to entrap air from the intake or fittings of the circulating system. Furthermore, the machining process tends to cause decomposition of the liquid in the machining .gap and some of the products of decomposition are gases. This occurs because the minute localized discharges occurring at extremely high temperatures cause decomposition of a portion of the dielectric fluid and certain portions of the electrode and workpiece as well. In electrical discharge machining, particularly in roughing operations, the size of particles removed from the workpiece tend to be relatively large and to settle in the bottom of the cavity being machined. The accumulation of particles in the gap region may cause bridging of the gap with resultant DC arcing or short circuiting of the gap. Either of these conditions gives rise to damage to workpiece and electrode and to excessive electrode wear. Efficient removal of the workpiece particles as well as the gas generated in the gap is therefore important.

Accordingly, it is the principal object of this invention to provide an improved electrode structure and coolant circulating system for electrical discharge machining and particularly to prevent gas developed from remaining in the workpiece gap.

A further object is to provide an improved coolant circulating system for eliminating undesirable gas and workpiece particles from the working gap.

Other objects and advantages will become apparent from the following specification which taken in conjunction with the accompanying drawings disclose preferred forms of practicing the invention.

In the drawings, in which reference characters have been used to designate like parts herein referred to:

FIG. 1 is a side view shown, partially in section of an electrical discharge machining tool with my improved fluid circulating system;

FIG. 2 is a rear view of this machine tool showing the fluid circulating pumps and fluid conduit arrangement for practicing one form of my invention;

FIG. 3 is a section on an enlarged scale showing the details of a gas dome that may be used;

FIG. 4 is a sectional view of the workpiece and electrode and special manifold for gas elimination directly at the electrode;

FIG. 5 is a sectional view of another type of electrode and a fluid circulating system therefor which may be 0perated in two different methods;

FIG. 6 is a bottom view of the FIG. 5 electrode showing the detail of the coolant hole pattern;

FIG. 7 is a sectional view of a similar electrode with a modified fluid circulation system;

FIG. 8 is a sectional view of a modified filter;

FIG. 9 is a sectional view of an electrode and a coolant circulation system therefor; and

FIG. 10 is a drawing of an electrode essentially similar to FIG. 9 in which the positions of the gap elements have been reversed.

Referring now to FIG. 1, it may be seen that the machine tool has a support structure 10 which includes a hollow base for containing the coolant fluid when not in use, a vertical column and overarm support for properly holding and positioning the electrode above the workpiece. The machine tool includes a bed or table 12 which is adapted to support a workpiece 14. A machining electrode 16 is mounted on a manifold 18 which, in turn, is fastened to ram platen 20. A movable ram 22 is driven vertically in slide 24 by piston rod 26. A hydraulic cylinder 28, for controlling the motion of piston rod 26, is secured to the overarm of machine frame 10. Hydraulic fluid is selectively supplied under pressure to either the top or bottom of cylinder 28 and exhausted from the opposite and thereby, driving piston rod 26 either down or up, respectively.

A hydraulic power pack 30 as shown in FIG. 2 furnishes hydraulic fluid under pressure to servo valve 32, which provides through manifold 34, hydraulic pressure to either line 36 or 38 connected respectively to the bottom and the top of cylinder 28. By means described in Patent No. 2,962,630, mentioned above, this hydraulic servo system automatically maintains the electrode in proximate position with the workpiece and advances the electrode into the workpiece as machining progresses.

Means is provided for rapidly filling a workpan 40 preparatory to machining and for rapidly emptying the pan after the marching operation, which includes fast fill motor driven pump 42 connected to workpan 40 by flexible line 44. An integral check valve is employed in or near pump 42 for preventing liquid from draining from the pan back to the base. This valve may be opened automatically and pump 42 reversed to drain the pan, or standpipe 46 may be removed.

In electrical discharge machining, the workpiece is submerged in the coolant liquid, confined by workpan 40. The level of this liquid above the workpiece is maintained by standpipe 46. A circulating pump 48 driven by motor 50 draws liquid from the reservoir in the base of machine for coolant circulation during machining. This liquid is forced under pressure through line 52, into filter 54 for clarifying the liquid and removing the particles or sludge which result from the machining operation. Filter 54 is secured to the machine base by clamps 56. The filtered output of filter 54 is delivered through hose 53 to a gas dome 60. This gas dome is also secured to the machine base by clamps. When a gas-eliminating manifold, as shown in FIG. 4, or the system shown in FIG. 5, is employed, this gas dome is sometimes unnecessary. Gas free liquid is provided to manifold 18 through flexible hose 62. A bypass line 64 and bypass control valve 66 are provided as shown for bypassing the unused portion of the liquid and the unwanted gas as shown in detail in FIG. 3.

There are two basic shapes or types of electrode used in electrical discharge machining. They are shown respectively as 68 in FIG. 4 and 70 in FIG. 5. The type of electrode shown as 68 may be thought of as convex and is characterized in the machining position by having no pockets or areas in which gas may be entrapped in the machining zone. Electrode 70 may be called concave in which pockets or reentrant portions such as 72 would form gas traps in a liquid dielectric with the electrode mounted in this position. All electrodes, regardless of complexity, may be defined as one or the other of these two types. In the position shown with the forward or protuberant portion of electrode 70 downward, gas will tend to rise into pockets 72 and, if it were not removed by some means, would remain trapped there during the entire machining operation or rather until it interrupted the machining operation because of the undesirable entrapped gas.

Electrode 68 is quite different, in that there are no concave portions or gas traps and any gas generated within the working gap tends to rise normally along the outer face of the electrode until it bubbles harmlessly out of the gap area. The circulating system for each of these two different types of electrodes and particularly the manifold construction for each is quite different. It is well known that all gases are many times lighter in weight than liquid and will always rise to the top of a container or the uppermost portion of a confined area. Any gas trapped in this manner in pockets 72 of concave electrode 70 is thus trapped and prevented from escaping from the work unless suitable means is provided.

Referring now to FIG. 3, it may be seen that a liquid inlet port 74 is provided in the top of gas dome 60. Cylinder body 76, bottom 78 and cover 80 confine the fluids under pressure as generated by the circulating pump. Any gas carried in the fluid through inlet 74 into gas dome 60 will tend to rise to the top of the gas dome. A bypass outlet port 82 is provided for connection to bypass line 64 and valve 66 as shown in FIG. 1 for bypassing a portion of the fluid. Circulating systems generally are provided with a flow rating in excess of the largest job required, and a portion of this flow is bypassed to achieve the desired flow rate and pressure. Through use of gas dome 60, any entrapped or generated gas in the fluid circulation system is bypassed first under considerable velocity through valve 66, since the gas has extremely low viscosity and high mobility through valve '66 in comparison to any liquid that may be employed. In this manner, gas dome 60 is always substantially filled with liquid 84 and nearly always some amount of excess liquid is discharging 4 through bypass outlet '82. A batfle plate 86 is provided to prevent gas from being carried downward by the normal turbulence of the liquid. A pressure outlet port 88 is provided in the bottom of the gas dome '60 and in this position is presented with nothing but gas-free liquid. Baflle 86 is supported in the gas dome by rod 90 which is tapped into bottom 78 and which extends through cover 80 for securing the cover against fluid pressure. A flexible O ring 92a is provided to seal cover 80 against body 76. A handwheel 96 is provided to tighten the cover and batfle assembly in place. In this manner, a very simple construction is provided having easy access for cleaning when the machine is shut down and the fluid pressure off. By simply turning handwheel 96 and removing cover 80, the entire assembly may be removed and tank 76 cleaned when necessary. In a very similar manner, handwheel 98 seals filter assembly 54 and may likewise be easily operated for simple replacement of plugged filter cartridges.

In many electrical discharge machining operations a gas dome such as 60 will be found suflicient to remove gas from the system. In these cases, it may be unnecessary to provide a special gas-eliminating manifold as shown in FIG. 4, particularly when used with convex electrodes. In most ECM operations and many EDM operations, such a manifold must be provided to achieve optimum machining. In some instances, a gas-eliminating manifold by itself is entirely suflicient to eliminate all entrapped gas both in the circulating system and in the working gap itself.

Referring now to FIG. 4, a typical manifold 18 is shown secured to machine platen 20 through use of T-slots 100, T-bolts 102, and nuts 104. Workpiece 14 is properly positioned on machine bed 12 and secured in place as is common in the art. During machining, fluid under the desired pressure is provided through inlet 106 to manifold 18. A bypass outlet 108 is provided and operates in a manner identical to that of outlet 82 and bypass valve 66 in FIGS. 1 and 3 in which the unwanted portion of the fluid is bypassed. Since this inlet and outlet are provided at the top of the manifold, the entrapped gas flows out of bypass outlet 108 and gas-free coolant is supplied under pressure to the machining gap through passages 110 in the electrode 68.

A coolant distribution system for a concave electrode is shown in a schematic form in FIG. 5. FIG. 7 shows a modified system wherein the fluid exhaust ports are sealed, as will be described. During normal machining operations, pump 112 supplies liquid under pressure through line 114 to coolant holes 116 drilled in the protuberant machining portions of electrode 70. This system may be provided with a gas dome as shown in FIG. 3, or a manifold somewhat similar to that shown in FIG. 4, but containing special sealing means for exhaust ports as shown in FIG. 7. A special manifold 118 is used, and this sealing means is usually provided when originally machining the manifold. In this method of operation, the forward coolant holes and exhaust coolant holes are laid out in the manifold and identified. A slot or series of slots such as 120 is then milled in the manifold providing chambers connecting all such coolant holes 116 together, frequently milling away all stock except in the immediate area of relief holes 122. In this manner, a series of bosses or protruding areas contact the back face of the electrode and thus seal off exhaust holes 122 from the pressure chamber. These exhaust holes are subsequently vented to atmosphere. The principles of construction of the manifold are still the same, in that the pressure inlet and bypass outlet are provided at the top of the manifold in exactly the same manner as shown in FIG. 4. Through this somewhat more involved system, gas free liquid is provided to the machining gap and any gas trapped in pockets 72 is exhausted through vents 122 to atmosphere.

FIG. 6 is a bottom view of the electrode 70. The electrodes shown in FIGS. 5 and 7 are the same.

Another quite different and advanced form of operation may be practiced in accordance with this invention in the system shown in FIG. 5 by reversing pump 112 in which line 114 becomes a suction line and line 124 becomes a pressure line, the exact opposite of that just described. In my copending application Ser. No. 313,369, filed Oct. 2, 1963, I show a specialized method of electrical discharge machining entitled, Multiple Discharge Machining. By special means outlined in that application, I maintain a layer of eroded particles in the working gap to act as an electrical or thermal cushion or barrier between the electrode and the workpiece. As outlined in.

that application, it is sometimes quite diflicult to maintain that barrier properly and coolant conditions must be ideal to provide a uniform barrier for a wide variety of machining operations. I have found in such machining operations that the direction of liquid flow is best operated in reverse to that normally provided. In other words, line 114 and associated lines become suction lines for drawing liquid away from the forwardmost portions of the electrode. In instances where this method is practiced, a filter is generally provided in the intake of pump 112to prevent sludge from being pumped through that unit or a special pump is provided capable of pumping the extremely fine abrasive grit produced in electrical discharge machining. The particles machined from the electrode and workpiece in this method are usually quite large and heavy and will settle readily to the bottom portion of a cavity being machined. Similarly, it is quite difficult with a normal volume of coolant flow to provide a uniform method of forcing these heavy particles upward. I find that by withdrawing liquid from the protruding portions of the electrode adjacent the bottom of the machined cavity, I can maintain a substantially uniform layer of these particles, thereby providing improved machining as outlined in the above application. Furthermore, I find that when coolant is provided with sufficient velocity to carry particles out of the gap in the normal direction, the extremely critical balance is destroyed and results are sometimes poor.

In this method of machining, liquid is drawn from the outer protuberant portions of the electrode and thus fluid must enter the gap through coolant holes 122. In this case, spacers 126 may be used in place of a manifold such as 118, thus providing a free path for coolant from the w-orkpan. When a manifold is not used then individual coolant suction lines or tubing are provided as shown by the individual branches in FIG. 5. Since the electrode is always submerged in liquid, this liquid is gas free. Since coolant holes 122 are now intake holes with coolant flowing in these holes, the size of these coolant holes 116 and 122 is quite critical. Normally, the forwardmost por- I tion of coolant hole 122, shown at 123, is approximately A" or larger. Coolant suction lines 114 are usually A3" or smaller and have a substantially longer passageway than that of portion 123. In addition, coolant hole 122 is counterbored to a larger diameter as shown to within approximately A3 to A of the machining face of the electrode. By constructing these coolant holes in this relationship, substantially all of the fluid pressure drop occurs in lines 114 and the relative pressure drop and velocity through orifice 123 is therefore much lower. With this specialized construction, gas that is entrapped in concave portion 72 will develop sufficient localized upward pressure to bubble through orifice 123 and up through opening 122 even though that coolant hole normally provides a coolant inlet rather than an outlet. Thus, localized gas bubbles are eliminated from this pocket even though the prevailing coolant flow is exactly opposite that presently employed in the art.

An additional advantage in employing this electrode construction for multiple discharge machining is that with normal coolant flow, the protuberant portions of the electrode tend to wear excessively and the particles of the barrier maintained in the gap tend to adhere to the electrode in the uppermost portion of the pocket or around coolant holes 123. This, of course, occurs with normal coolant flow and is completely eliminated by providing coolant flow in the opposite direction as described above, since this layer of machined particles is flushed away from the uppermost portion and additionally settles by gravity to the deepest portions of the cavity to be withdrawn through lines 114. I have thereby provided gas-free machining even in this extremely specialized method.

In the foregoing examples, I have shown the electrode mounted above the workpiece and coolant holes machined in the electrode. In certain specialized applications, particularly with electrodes that would by this definition be concave and as shown hereinafter in FIGURE 10, the work-piece is mounted above the electrode and on these occasions coolant holes are then sometimes provided in the workpiece. It may readily be seen that this same method may be employed whether the electrode or work- 7 piece is mounted in the uppermost position, the essential characteristics being described above for either form of operation.

FIG. 8 shows a construction of a special filter assembly which may replace filter 54 in FIG. 1. FIG. 1 shows a standard filter assembly and a gas dome constructed to eliminate entrapped gas in the system. The need for this special dome is eliminated if the filter assembly is especially constructed in accordance with the teachings of my invention. Filter assembly 126 (shown in FIG. 8) comprises a body 128 which is of cylindrical construction and a base 130. An external pipe flange 132 and internal mounting flange 134 are welded to base to provide a fluid outlet from the bottom of the filter. A hole 136 is drilled in mounting flange 134 to provide filtered liquid outlet from the inside of filter element 138.

The filter element assembly itself is composed of end plates 140 and 142 and a pleated paper filter element 144 bonded to the end plates. In this example, I show a filter element known commercially as a pleated paper filter element; however, any suitable filter element or bank or elements may be readily substituted. A rod 146, threaded at each end, extends through the center of the filter element for sealing it in place by means of nut 148, retaining ring and gaskets 152 at the top of the element and at the bottom of the element. Rod 146 extends through cover 154 for securing the cover in place 'by means of handwheel 156.

This construction provides a fluid tight filter casing and a chamber for unfiltered coolant which flows in through inlet 158. The inside of filter element 138 is sealed from this chamber as shown and unfiltered coolant entering the inlet 158 at the top of the filter assembly must pass through the pleated paper 144 to the inside of element 138. Filtered gas-free liquid leaves the inside of the filter element through port 136 to outlet 160.

Bypass outlet 162 is provided near the top of the filter case for bypassing the undesired gas and the excess liquid exactly as the gas dome assembly 60 shown in FIG. 3. If the filter is specially constructed in this manner, gas dome 60 may therefore be eliminated, since the exact function of the dome is now achieved by this special filter construction.

FIGURE 9 shows an example of an electrode structure and coolant circulating system in which removal of workpiece particles from the gap is of special importance. The pump 112 provides filtered dielectric coolant flow to the gap as indicated by arrow. Conduits 114 and 124 are connected to the suction and pressure sides of pump 112 'as shown. Electrode 70 is of the type previously described in connection with FIGS. 5 and 7 and has spaced protuberant and reentrant portions on its machining face. Suction conduit 114 terminates in a plurality of passages 116, each extending through a different protuberant portion of electrode 70. A passage 116a extends between the back face of the electrode 70 and each reentrant portion of the electrode machining face. It will be seen that with suction applied at the forwardmost portion of each protuberant portion, the coolant flow will be downwardly through passages 116a which passages are of greater cross section than passages 116. The particles collecting in the machining gap are thus rapidly removed to permit machining at the optimum rate with a minimum of electrode wear.

FIGURE 10 shows an electrode and coolant circulation system with the workpiece 17 mounted above the electrode 70 for advancement by servo means such as hydraulic cylinder 28 to permit material removal. In this embodiment the particles removed from the workpiece will tend to settle on the electrode machining face in the reentrant or concave portions. A passage 116b extends from the reentrant portion and is connected through conduit 114 to the suction side of pump 112. Each protuberant portion of the electrode 70 has extending therethrough a passage 116 through which coolant is provided under pressure from conduit 124. Passages 116, 1161; may alternately be made of the same cross sectional size. It will thus be seen that the direction of coolant flow as related to the protuberant and reentrant portion of the electrode machining face is in a direction to maintain the gap free of machined particles. This flow is maintained in such a manner that the gravitation forces which tend to remove the particles from the cavity being machined are best utilized in that removal.

I have found that an electrode and coolant circulation system particularly as illustrated and described in connection with FIGURES 9 and 10 gives rise to a greatly reduced rate of electrode wear i.e. one approaching a nowear condition. Improvement in this respect has been most marked with electrodes of graphite composition but it is also significant when used with other electrode materials.

It will thus be seen that I have shown and described a new and improved method for electrical discharge machining and preferred examples of apparatus for carrying on the process.

I claim:

1. In an electrical discharge machining apparatus for machining a conductive workpiece by a tool electrode across a dielectric fluid filled gap, means for mounting said workpiece above said electrode juxtaposed to its machining face and providing relative movement therebetween during machining, said electrode having at least one protuberant portion and one reentrant portion on its machining face, a different passage extending through each of the aforesaid portions, a fluid pressure pump having an inlet and an outlet, said outlet connected to said passage through said protuberant portion for providing pressurized dielectric fluid flow toward said workpiece and said inlet connected to said passage through said reentrant portion to remove dielectric fluid and machined particles from said gap.

2. In an electrical discharge machining apparatus for machining a conductive workpiece by a tool electrode across a dielectric fluid filled gap, means for mounting said electrode above said workpiece and providing relative movement therebetween during machining, said electrode completely immersed in said fluid 'and having at least one protuberant portion and one reentrant portion on its machining face, a different passage extending through each of the aforesaid portions, said passage extending through said protuberant portion having a substantially smaller cross-sectional area than said passage extending through said reentrant portion, and a fluid pressure pump having its inlet connected to said passage through said protuberant portion for removing dielectric fluid including machined particles from said gap.

3. In an electrical discharge machining apparatus for machining a conductive workpiece by a tool electrode across a dielectric fluid filled gap, means for mounting said workpiece above said electrode juxtaposed to its machining face and providing relative movement therebetween during machining, said electrode having at least one protuberant portion and one reentrant portion on its machining face and a different passage extending through each of the aforesaid portions, an electrical power supply operatively connected across said gap for providing unidirectional machining pulses thereto of a polarity maintaining said electrode positive relative to said workpiece, a fluid pressure pump having an inlet and an outlet, said outlet connected to said passage through said protuberant portion for providing pressurized dielectric fluid flow toward said workpiece and said inlet connected to said passage through said reentrant portion to remove dielectric fiuid including machined particles from said gap.

4. In an electrical discharge machining apparatus for machining a conductive workpiece by a tool electrode across a dielectric fluid filled gap, an electrical power supply operatively connected to said gap for providing unidirectional machining pulses thereto of a polarity maintaining said electrode positive relative to said workpiece, means for mounting said electrode above said workpiece and providing relative movement therebetween during machining, said electrode completely immersed in said fluid and having at least one protuberant portion and one reentrant portion on its machining face, a different passage extending through each of the aforesaid portions, said passage extending through said protuberant portion having a substantially smaller cross-sectional area than said passage extending through said reentrant portion, and a fluid pressure pump having an inlet, said inlet connected to said passage through said protuberant portion for removing dielectric fluid including machined particles from said gap.

References Cited UNITED STATES PATENTS 2,785,279 3/1957 Williams 219-69 2,885,529 5/1959 Nelson 21969 2,308,860 1/1943 Clerk 219-69 X 3,035,151 5/ 1962 Weglarz 2l969 RICHARD M. WOOD, Primary Examiner.

'R. F. STAUBLY, Assistant Examiner. 

